Method of producing a wireless communication device

ABSTRACT

A method for manufacturing wireless communication devices for use in tracking or identifying other items comprises a number of cutting techniques that allow the size of the antenna for the wireless communication device. Further, the chip for the wireless communication device is nested so as to be flush with the surface of the substrate of the wireless communication device. Rollers cut the tabs that form the antenna elements. In a first embodiment, a plurality of rollers are used, each on effecting a different cut whose position may be phased so as to shorten or lengthen the antenna element. In a second embodiment, the rollers are independently positionable to shorten or lengthen the antenna element.

RELATED APPLICATION

This application claims priority and the benefit of U.S. ProvisionalPatent Application Ser. No. 60/375,249 filed Apr. 24, 2002, which isincorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a method of manufacturing a wirelesscommunication device for use in communication of information concerningan item containing the wireless communication device.

BACKGROUND OF THE INVENTION

It is often desired to track and identify items, such as packages,containers, and the like, and to communicate information concerning suchitems wirelessly. One method of tracking and providing informationconcerning packages is to attach a wireless communication device, suchas a radio frequency identification (RFID) transponder or otheridentification device, to packages or items. The informationcommunicated concerning the packages or items may include an expirationdate, “born on” date or date of manufacture, lot number, trackinginformation, or other manufacturing information, and the like. Awireless communication device may be attached to an individual package,to a container containing multiple packages, or other item as thesituation merits.

Recent advances in the miniaturization of wireless communicationelectronics have enabled the creation of small chips, containingintegrated circuits, that are well suited for use in these wirelesscommunication devices. However, these chips still need antennas tocommunicate to a remotely positioned interrogator. Numerous potentialantennas exist that may be coupled to the chip for this purpose.

It is expected that the demand for such devices will rapidly increase asindustries realize the versatility and utility of the wirelesscommunication devices. To meet this demand, automated manufacturingprocesses are needed. Further, the process contemplated should provide awireless communication device well suited for integration with the itemto be tracked and one that may have the ability to communicate atmultiple frequencies if desired.

SUMMARY OF THE INVENTION

In a first aspect, the present invention provides a number ofembodiments designed to pick up chips from a carrier tape and positionthe chips on an adhesive production line for later incorporation into awireless communication device.

In a second aspect, that may be used in conjunction with the firstaspect comprises a combination of positioning a conductive material on aroll, cutting the conductive material to the desired shape, and peelingthe conductive material from an underlying carrier material. In oneembodiment of this aspect, a single roller performs the entire cut. In asecond embodiment of this aspect, three separate rollers performdifferent cuts, allowing the size of the tabs created to be varied asneeded or desired.

Another aspect comprises using two selectively spaced rollers to adjustthe size of the tab created. In an exemplary embodiment, a testingdevice may assess the capacitance of the elements of the dipole with aground layer or without a ground layer to give an estimate of thethickness and/or dielectric constant of the substrate to which the chipis being applied. Each roller may be moved independently, increasing ordecreasing the size of the tab while assessing the effective capacitanceuntil a desired value is achieved for maximum antenna performance. Uponreaching the desired values, the tabs are cut to create the antenna.

As yet another aspect, the present invention may insert a wirelesscommunication chip into a substrate such that the chip does not protrudefrom the surface of the substrate. An exemplary embodiment includes,punching a hole in the substrate, positioning tabs to form a dipoleantenna overlapping the newly formed hole, and positioning the chip inthe hole. The chip may be attached to the tabs by a low melting pointsolder, a conductive adhesive, welding, or a mechanical bond.

The aspects are mutually cooperative and allow a roll-to-rollmanufacturing process to be automated for the creation of the wirelesscommunication devices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top plan view of a wireless communication deviceassembled according to the present invention;

FIG. 2 illustrates a side elevational view of a carrier tape loaded withwireless communication chips;

FIG. 3 illustrates a side schematic view of a first technique toposition chips on an adhesive production line;

FIG. 4 illustrates a side schematic view of a second technique toposition chips on an adhesive production line;

FIG. 5 illustrates a more detailed view of the interface between theroller and the carrier tape of FIG. 4;

FIG. 6 illustrates a side view of a first cutting technique for creatingantenna elements for wireless communication devices;

FIG. 7 illustrates a top view of the first cutting technique of FIG. 6;

FIG. 8 illustrates a side view of a second cutting technique forcreating antenna elements for wireless communication devices;

FIG. 9 illustrates a top view of the laminate during different stages ofthe cutting of FIG. 8;

FIG. 10 illustrates a side view of a third cutting technique forcreating antenna elements for wireless communication devices;

FIG. 11 illustrates a top view of the third cutting technique of FIG.10;

FIG. 12 illustrates a top view of the third cutting technique of FIG. 10with the rollers spread;

FIGS. 13A and 13B illustrate top views of the tape before and aftercutting in the process of FIGS. 10–12;

FIG. 14 illustrates a first cross-sectional view of a positioningtechnique for a chip to be used in a wireless communication device;

FIG. 15 illustrates a top plan view of an antenna element positioned ona substrate;

FIG. 16 illustrates a side view of the antenna element of FIG. 15 with achip positioned above it prior to positioning;

FIG. 17 illustrates a side view of the antenna element of FIG. 16 withthe chip positioned;

FIG. 18 illustrates an exemplary roller technique to attach the chips tothe substrate of the wireless communication device;

FIG. 19 illustrates a more detailed view of the chip being attached tothe substrate; and

FIG. 20 illustrates an exemplary block diagram of an entire productionprocess using the techniques of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a method of manufacturing wirelesscommunication devices such as those used in co-pending, commonlyassigned U.S. patent application Ser. Nos. 09/678,271 and 09/678,630,entitled “Wireless Communication Device and Method” and “Multi-BandWireless Communication Device and Method” respectively, both of whichwere filed on Oct. 3, 2000 and are incorporated herein by reference intheir entireties. In particular, the present invention allows variationsin the size of the tabs used for antenna elements in the wirelesscommunication devices.

Some wireless communications devices have both transmit and receivecapability and can be used in the present invention. A typical exampleof such a device is described in U.S. Pat. No. 5,585,953, entitled“IR/RF radio transceiver and method,” incorporated herein by referencein its entirety. Other wireless communication devices have receivecapability and use the energy received to communicate back, such asdescribed in U.S. Pat. No. 6,078,259 entitled “Radio frequencyidentification tag,” incorporated herein by reference in its entirety.Such passive devices may likewise be used with the present invention.The wireless communication device in the present invention can be anytype of device that allows reception of wireless, electroniccommunications and is able to communicate in response thereto. Bothtypes of wireless communication devices are sometimes referred to hereinand in the art as transponders. The terms are used equivalently herein.

FIG. 1 illustrates a wireless communication device 10, such as thatdescribed in the previously incorporated applications. In particular,wireless communication device 10 comprises a substrate 20, a wirelesscommunication chip 30, and one or more tabs 40, to serve as an antenna60 for wireless communication device 10. Tabs 40A, 40B may beconstructed out of any type of material so long as the material isconductive. Such material be a ferrous material, including metal, steel,iron, or the material may be aluminum or other type of conductingmaterial.

Tabs 40 may also be constructed from a tape impregnated with metalloaded ink, as described in U.S. Pat. No. 5,566,441, entitled “Attachingan electronic circuit to a substrate,” incorporated herein by referencein its entirety. In one embodiment of the present invention, asillustrated in FIG. 1, tabs 40A, 40B are made from a foil tape 42, 52respectively as is well understood in the art.

An optional ground plane (not shown) may be oppositely positioned onsubstrate 20 if needed or desired. Substrate 20 may be almost anymaterial, but is most likely a plastic or similar material.

Wireless communication chip 30 may comprise a device from INTERMEC asused in their Intellitag® labels and those devices from SCS as used intheir DL100 label although other devices are certainly possible,especially in light of the present invention's suitability to bothactive and passive wireless communication devices 10. Wirelesscommunication chip 30 may comprise a controller, memory, a battery, asensor, and other conventional components such as those described in thepreviously incorporated applications.

Tabs 40A, 40B together comprise dipole antenna 60. In this particularembodiment, tabs 40A, 40B are asymmetrical with respect to one anotherto form an asymmetrical dipole antenna. An asymmetrical dipole antenna60 is an antenna having a first tab 40A, or first pole, different inshape, including, but not necessarily limited to length, width, volume,and/or density, from the second tab 40B, or second pole.

Tabs 40A, 40B may also be coupled to a slot to form a slot antenna (notshown). Alternatively, a single tab 40 may be used as a monopole antennagiven the appropriate ground plane (not shown). While the presentinvention is primarily directed to dipole antenna tab structures, itshould be appreciated by those in the art that some of the techniquesmay be equally applicable to a single tab 40 arrangement, or anarrangement having more than two tabs 40A, 40B.

The present invention focuses on techniques to manufacture thesewireless communication devices 10. There are several different aspectsto the manufacturing process. The first is properly positioning thewireless communication chip 30 for later processing, and is discussed inthe chip positioning section below. The second is the creation of thetabs 40 that from the antenna 60, addressed in a separate section below.The last is the merging of the chip 30 with the antenna 60 to form thewireless communication device 10, discussed in the mounting techniquessection below.

Chip Positioning Techniques

FIG. 2 illustrates an exemplary carrier tape 100 comprising an adhesivesealing layer 102 and a container layer 104. Container layer 104comprises a plurality of containers or pockets 106 having wirelesscommunication chips 30 disposed therein. Carrier tape 100 may be madefrom any number of materials and is available from a number ofmanufacturers such as Tek Pak. Details can be found at www.tekpak.com.Adhesive sealing layer 102 initially seals the chips 30 within thecontainers 106, protecting them from environmental vagaries.Subsequently, when desired, adhesive sealing layer 102 peels off ofcontainer layer 104, leaving the contents of the containers 106 exposedfor further processing.

There are two specifically contemplated techniques to remove the chips30 from the carrier tape 100 for later mounting on the wirelesscommunication device 10. Other techniques are also contemplated toenable the roll-to-roll continuous automation process of the presentinvention.

A first technique is illustrated in FIG. 3. Chip positioning system 110comprises a waste roller 112, a first roller 114, and a second roller116. Carrier tape 100 is fed to rollers 114, 116 simultaneously with anadhesive line 118. Waste roller 112 wraps adhesive sealing layer 102therearound, exposing chips 30 within the containers 106 (FIG. 1).Rollers 114, 116 may be oval shaped and rotate at a frequency so as tospace chips 30 appropriately on adhesive line 118. The proximity of theroller 114 to roller 116 pushes the chip 30 out of the container 106 andto the sticky surface of the adhesive line 118. This removes the chip 30from the container 106 and allows the adhesive line 118 with the chips30 to be passed downstream for further processing.

A second technique is illustrated in FIGS. 4 and 5. As illustrated inFIG. 4, chip positioning system 110A comprises a waste roller 112, atoothed roller 120 having teeth 122 and may have an optional secondroller (not shown) comparable to second roller 116. Carrier tape 100 isfed to the roller 120 with waste roller 112 removing the adhesivesealing layer 102 as previously described. Now with reference to FIG. 5,wherein a more detailed view of the interface between the teeth 122, thecontainers 106, the chips 30, and the adhesive line 118 is illustrated,it can be seen that a tooth 122 pushes through the floor 105 of thecontainer 106, pushing chip 30 upwardly to contact the adhesive line118. Again, this removes the chip 30 from the container 106 and allowsthe adhesive line 118 with the chips 30 to be passed downstream forfurther processing.

Manufacture of Tabs For Antenna

Concurrent to the positioning of the chips 30 on the adhesive line 118,tabs 40 may be created for the wireless communication device 10. Thissection focuses on techniques by which the tabs 40 may be created thatare again well suited for use in the roll-to-roll automatedmanufacturing process of the present invention.

A first technique for the creation of tabs 40A, 40B is illustrated inFIGS. 6 and 7. FIG. 6 illustrates a tab production system 130,comprising a pair of rollers 132, 134 oppositely positioned on eitherside of a production line 140. Top roller 132 may comprise a die cuttingroller while bottom roller 134 may be a driving roller to push materialthough rollers 132, 134. It should be appreciated that rollers 132, 134may be reversed if production line 140 is inverted. Production line 140may also comprise a backing layer 142, an adhesive (not shownexplicitly) and a conductive foil 144, such as a copper foil, analuminum foil, or the like. As production line 140 passes throughrollers 132, 134, die cutting roller 132 cuts conductive foil 144 intoone or more tabs 40. In this particular embodiment, die cutting roller132 cuts conductive foil 144 into two tabs 40A, 40B. Waste foil 146 ispeeled from backing layer 142 while tabs 40A, 40B and backing layer 142continue for further processing. Tabs 40 are then used to form antennaelements for antenna 60 on the wireless communication device 10 asexplained below.

To accommodate substrates 20 that may have varying dielectric constantsand/or thicknesses (such as may occur when switching materials havingdifferent dielectric constants forming substrate 20) variations may needto be made to the dimensions of tabs 40A, 40B to produce the optimumread range at the desired operating frequency. To ensure optimal antenna60 performance using tabs 40A, 40B with chip 30, energy transfer shouldbe maximized between chip 30 and tabs 40A, 40B to maximize emittedradiation from tabs 40A, 40B. To ensure maximum energy transfer, theimpedance of tabs 40A, 40B must be substantially matched to theimpedance of chip 30.

Further information on impedance matching between wireless communicationdevices and antennas is described in the previously incorporated U.S.patent application Ser. Nos. 09/678,271 and 09/678,630, and co-pendingU.S. patent application Ser. No. 10/125,786 entitled “Tuning techniquesfor a slot antenna,” filed on Apr. 18, 2002 filed by the same assigneeas the present application and incorporated herein by reference in itsentirety.

A first technique to address this situation is illustrated in FIGS. 8and 9. In this technique, a plurality of rollers 200, 202, 204 is used.In particular, tab production system 130A receives production line 140.A first roller 200 makes an initial cut 206 in conductive foil 144. Thisinitial cut 206 comprises the inner portions of tabs 40A, 40B. A secondroller 202 makes a second cut 208 in conductive foil 144 that completesthe creation of one of tabs 40A, 40B (in this case tab 40A). Second cut208 overlaps to a certain extent initial cut 206 of first roller 200. Athird roller 204 makes a third 210 cut in conductive foil 144 thatcompletes the creation of the other one of tabs 40A, 40B (in this casetab 40B). Third cut 210 overlaps to a certain extent the initial cut 206of first roller 200. Note that the precise order of the cutting byrollers 200, 202, 204 may be varied. For example, a first cut couldbegin on the left edge, beginning tab 40A, a second cut ends tab 40A andbegins tab 40B, and the third cut ends tab 40B. Other variations arealso contemplated.

The technique of FIGS. 8 and 9 allows the sizes of the tabs 40A, 40B tobe varied by varying the phases of rollers 202, 204 with respect tofirst roller 200. Thus, if a longer tab 40A is desired, second roller202 is phased such that there is little overlap between the cuts 206,208. If a shorter tab 40A is desired, second roller 202 is phased suchthat there is substantial overlap in the cuts 206, 208. The sameprinciple applies to the size of tab 40B, but the phase of third roller204 is modified to achieve the desired amount of overlap between thecuts 206, 210. Allowing for differently sized tabs 40A, 40B allowsoptimal antenna 60 performance as previously explained. It should beappreciated that rollers 200, 202, 204 rotate at the same rate to avoidundesired phase changes between rollers 200, 202, 204. This technique isespecially well suited for situations in which substrate 20 variesbetween wireless communication devices 10. In one embodiment, it isexpected that at a 200 ft/min rate of movement of production line 120,and an antenna 60 dimension of approximately 68 mm×16 mm outsidedimensions, thus giving about 60 antennas 60 per foot, approximately12,000 antennas may be made per minute.

An alternate technique to provide variations in the size of tabs 40A,40B is illustrated in FIGS. 10–13B. In this technique, production system130B comprises a first roller 300 and a second roller 302, each of whichis independently movable relative to one another. This technique isbetter suited for situations in which substrate 20 on which wirelesscommunication device 10 is to be placed varies, as this technique allowstesting on the fly to get the desired impedance for antenna 60 inconjunction with substrate 20. Rollers 300, 302 receive a productionline 140A (illustrated in FIG. 13A) comprising a backing material 130with tabs 40A, 40B, and chip 30 disposed thereon. In contrast to theother techniques previously discussed, this technique positions, butdoes not specifically require, chip 30 mounted with the elements thatform tabs 40.

Production line 140A passes under first roller 300 and second roller 302to deposit the tabs 40 and the chip 30 onto the substrate 20. Rollers300 and 302 may initially be close together as illustrated by dimension‘X’ in FIGS. 10 and 11. During the deposit of tabs 40A, 40B on substrate20, a low signal level and low frequency radiator 138, operating at, forexample, 125 kHz, assesses the capacitance of tabs 40A, 40B inconjunction with substrate 20 and with or without ground plane 306 (FIG.10). This provides an estimate of the thickness and dielectric constantof substrate 20. Tabs 40A, 40B may be sized appropriately to provide thedesired capacitance by moving the rollers 300, 302 to insure optimalantenna 60 performance as previously discussed.

As illustrated by the difference between FIGS. 11 and 12, rollers 300,302 may be spread if larger tabs 40A, 40B are required. After thetesting equipment determines that the tabs 40 are appropriately sized togive the desired performance to antenna 60, a cut is made and tabs 40A,40B are mounted on substrate 20. This cut may be made with a die, aknife, a laser, or other appropriate cutting tools (none shown). It maybe desirable to test capacitance by changing one and then the other tab40A, 40B as needed or desired. As can be seen in FIG. 13B, the cutremoves tabs 40A, 40B and a portion of the backing material 130 tocreate hole 121, leaving tab residuals 40′, 50′.

As previously noted, some of the above techniques may be occurringconcurrently with the positioning of the chips 30 on the adhesive line118. The following section deals with mounting the chips 30 on thewireless communication device 10 after the antenna 60 has beenpositioned thereon.

Mounting Techniques

One technique is illustrated in FIG. 14. In particular, a hole 22 ispunched into substrate 20. Hole 22 is any type of cavity in substrate 20or any type of geometry such that wireless communication chip 30 may bewholly or partially placed inside such cavity. Hole 22 may have taperedtop edges 24 that taper from a wide opening 26 to a narrow mouth 28. Thesize of narrow mouth 28 may be the same or smaller in size than thewidth of wireless communication chip 30, so that wireless communicationchip 30 rests in hole 22 at the point where narrow mouth 28 begins.

Foil tape 42, 52 overlaps edges 24 so that tape 42, 52 extends partiallyinto hole 22. Chip 30 is then inserted in the direction of the arrowinto the hole 22. Hole 22 may be designed to allow chip 30 to sit flushwith upper surface 21 of substrate 20 without substantially protrudingtherefrom, as is illustrated in FIG. 14. This reduces the profile ofsubstrate 20 and protects chip 30 from some inadvertent harm. Hole 22may also be designed to allow chip 30 to sit fully below upper surface21 or to protrude slightly from hole 22 depending on the design and sizeof hole 22, edges 24, and mouth 28.

A number of techniques exist to attach chip 30 to tabs 40A, 40B. A firsttechnique comprises using a low melting point solder. Tape ends 44, 54of foil tape 42, 52 may be pre-loaded with a solder paste. Chip 30 isthen simply dropped onto the paste (not shown), and the solder (notshown) is melted to form connectivity between tabs 40A, 40B and chip 30.Appropriate methods to form the solder joint comprise the use ofinfrared radiation to heat the joint locally, or pushing chip 30 intothe paste with pins 32 of chip 30 preheated. Preheating of pins 32allows the solder to remain in a liquefied state longer after initialmelting so that solder may more easily flow to more surface area of tabs40A, 40B and around pin 32 to form a stronger bond. Such preheating maybe accomplished by any technique, including use of a preheating toolthat emits heat such as a hot gas jet or the like.

An alternative technique for attaching chip 30 to tabs 40A, 40Bcomprises the use of a conductive adhesive (not shown). The adhesiveforms a bond between tabs 40A, 40B and chip 30, and the conductivity ofthe adhesive ensures electrical continuity between tabs 40A, 40B andchip 30. Either a suitable conductive adhesive can be applied byprinting to ends 44, 54 of tape 42, 52 prior to assembly, or chip 30 maybe pushed onto a pressure sensitive conductive adhesive on top surfaces46, 56 of tape 42, 52. It may be advantageous, but not required to usean adhesive that can be cured rapidly. For example, an adhesive cured bya flash of ultraviolet (UV) light would be appropriate. Examples ofconductive adhesives include isotropic conductive adhesives, conductivesilicones, and anisotropic conductive adhesives. The interested readeris directed to Electrically Conductive Adhesives Characteristics andApplications, a Loctite Corporation publication available atwww.loctite.com that is hereby incorporated by reference in itsentirety. Further information may also be found at the followingwebsite:www.chemical.felpro.com/electronics/elec_tech_index.html#eleccond.

Yet another alternative is illustrated in FIGS. 15–17. In thisembodiment, the tape 42 has one end sliced into a plurality of fingers48. Note that the fingers 48 are made from the same material as the tape42, but include cuts 49 between the fingers 48. The fingers are thenplaced proximate the hole 22. A top view of the tape 42, the fingers 48,and an exemplary positioning relative to the hole 22 is illustrated inFIG. 15. With that arrangement in place, it is now possible to mount thechip 30.

Chip 30, and particularly pins 32 thereof, are heated above the yieldpoint of substrate 20 and positioned over substrate 20 (FIG. 16). Pins32 are then forced into substrate 20 with fingers 48 wrapping aroundpins 32, as illustrated in FIG. 17. The heat of pins 32 melts substrate20, which then cools around tape 42 and pins 32 forming an effectivemechanical bond. Also note that this technique could also be done on theother tab 40B (not shown) in a similar fashion. Note that both tabs 40A,40B should be in place prior to this insertion.

Still another alternative would be to weld or tack pins 32 to tape 42,52 using a suitable tool. The tool presses chip 30 into surface 21 ofsubstrate 20. A high current may be passed through pins 32, using a lowvoltage pulse therethrough to form the weld. A lower voltage pulse isdesirable so as to not apply a damaging voltage to chip 30. A modifiedchip 30 with a single thin foil (not shown) rather than multiple pins 32may also be used for this technique. This technique may be better suitedfor chips 30 having an aluminum thin foil rather than a copper thinfoil, since aluminum has a melting point temperature lower than copperthereby allowing use of a current that is lower in Amperes.

With all of these embodiments, a sealing layer (not shown) may also beplaced onto substrate 20 and over chip 30 to hold chip 30 firmly in itsdesired location. This sealing layer may be an epoxy, but may instead bea robust plastic such as polyimide, Mylar, or polypropylene. Theseplastics may be attached by adhesives or by thermal welding as needed ordesired.

It should be noted that extra layers may be added to wirelesscommunication device 10 after or in place of the sealing layer. Forexample, a paper layer for printing or plastic layers may be added tothe structure. Such sealing layer or layers may be applied ontosubstrate 20 using any type of label printing machine.

For almost any of the above styled processes, the chip 30 may bepositioned on the substrate 20 with rollers as illustrated in FIGS. 18and 19. Chip merging system 160 is illustrated schematically in FIG. 18and comprises a first and second heat and pressure roller 162, 164.These rollers 162, 164 may perform the thermal welding alluded to above.Adhesive line 118 with chips 30 disposed thereon passes between rollers162, 164 and mates with substrate 20, and particularly hole 22 ofsubstrate 20 as better seen in FIG. 19. Tabs 40 have been prepositionedon substrate 20 prior to the introduction of the chip 30 thereto. Chip30 may be secured to the tabs 40 and the substrate 20 by any of themeans previously discussed as needed or desired.

The above-mentioned techniques are useful with a number of othermanufacturing techniques. Of particular interest is the creation of tabs40A, 40B. This may be done before, concurrently with, or after thecreation of hole 22 in substrate 20 as needed or desired.

The present invention is well suited for “roll to roll” processes,making the automation of the present invention easy. As illustrated inFIG. 20, the chip 30 positioning process may be occurring concurrentlywith the tab 40 creation process. The tabs are then positioned on thesubstrate 20 through an appropriate means as is well understood. Finallythe two production lines merge and the chip 30 may be positioned on thesubstrate 20. Furthermore, the automation may test and mark defectiveparts as needed or desired.

The present invention may, of course, be carried out in other specificways than those herein set forth without departing from the scope andthe essential characteristics of the invention. The present embodimentsare therefore to be construed in all aspects as illustrative and notrestrictive and all changes coming within the meaning and equivalencyrange of the appended claims are intended to be embraced therein.

1. A method of producing a wireless communication device, comprising:adjustably cutting a first tab for use as a first antenna element;adjustably cutting a second tab for use as a second antenna element; andsecuring said first and second tabs to a wireless communication chip,thereby forming a wireless communication device, wherein the first andsecond tabs are adjustably cut according to a determined electricalcharacteristic.
 2. The method of claim 1, further comprising creating acavity in a substrate.
 3. The method of claim 2, further comprisinginserting said wireless communication chip into said cavity such thatsaid wireless communication chip is flush with an upper level of saidsubstrate.
 4. The method of claim 2, further comprising inserting saidwireless communication chip into said cavity such that said wirelesscommunication chip is wholly placed inside said cavity.
 5. The method ofclaim 2, further comprising inserting said wireless communication chipinto said cavity such that said wireless communication chip is partiallyplaced inside said cavity.
 6. The method of claim 2, further comprisinginserting said wireless communication chip into said cavity such thatsaid wireless communication chip is placed below an upper surface ofsaid cavity.
 7. The method of claim 2, further comprising creating saidcavity with tapered edges at an upper surface of said substrate thattaper from a wide opening to a narrow mouth.
 8. The method of claim 7,further comprising sizing said narrow mouth relative to said wirelesscommunication chip so that, when inserted into said cavity, saidwireless communication chip rests in said cavity at the point where saidnarrow mouth begins.
 9. The method of claim 2, wherein said first andsecond tabs are adjustably cut before said cavity is created.
 10. Themethod of claim 2, wherein said first and second tabs are adjustably cutconcurrently with creation of said cavity.
 11. The method of claim 2,wherein said first and second tabs are adjustably cut after said cavityis created.
 12. The method of claim 1, wherein securing said first andsecond tabs to a wireless communication chip comprises adhering with aconductive adhesive said first and second tabs to the wirelesscommunication chip.
 13. The method of claim 12, further comprisingapplying said conductive adhesive to ends of said first and second tabsprior to securing said first and second tabs to said wirelesscommunication chip.
 14. The method of claim 12, further comprisingapplying a pressure sensitive conductive adhesive to a top surface ofthe first and second tabs and pushing said wireless communication chiponto said pressure sensitive conductive adhesive.
 15. The method ofclaim 12, further comprising curing said conductive adhesive to securesaid first and second tabs to said wireless communication chip.
 16. Themethod of claim 15, wherein said conductive adhesive is cured byultraviolet light.
 17. The method of claim 1, wherein securing saidfirst and second tabs to a wireless communication chip comprises weldingsaid first and second tabs to the wireless communication chip.
 18. Themethod of claim 1, wherein securing said first and second tabs to awireless communication chip, further comprises: creating fingers on saidfirst and second tabs; heating pins on the wireless communication chip;and inserting said heated pins into a substrate such that the fingers onsaid first and second tabs wrap around said pins and a mechanical bondis formed around said pins.
 19. The method of claim 1, wherein securingsaid first and second tabs to a wireless communication chip comprisessoldering the wireless communication chip to the first and second tabs.20. The method of claim 19, wherein soldering the wireless communicationchip to the first and second tabs comprises applying a soldering pasteto said first and second tabs.
 21. The method of claim 20, whereinsoldering the wireless communication chip to the first and second tabsfurther comprises using infrared radiation to heat the soldering paste.22. The method of claim 20, further comprising heating pins on saidwireless communication chip and inserting said heated pins into saidsoldering paste.
 23. The method of claim 1, wherein said electricalcharacteristic is capacitance.
 24. The method of claim 23, wherein saidelectrical characteristic is determined by assessing the capacitance ofsaid first and second tabs in conjunction with a substrate on which thetabs are deposited.
 25. The method of claim 23, wherein said first andsecond tabs are adjustably cut to obtain a desired capacitance.
 26. Themethod of claim 1, wherein said electrical characteristic is impedance.27. The method of claim 26, wherein said first and second tabs areadjustably cut to obtain a desired impedance.
 28. The method of claim27, wherein said desired impedance is an impedance of said first andsecond antenna elements and said desired impedance matches an impedanceof said wireless communication chip.
 29. The method of claim 1, whereinsaid electrical characteristic is determined on the fly while producingsaid wireless communication device.
 30. The method of claim 1, whereinsaid cutting of said first and second tabs is automatically adjustedsubsequent to determining said electrical characteristic.
 31. The methodof claim 1, wherein securing said first and second tabs to a wirelesscommunication chip comprises tacking said first and second tabs to thewireless communication chip.
 32. The method of claim 1, wherein securingsaid first and second tabs to a wireless communication chip comprisespassing a current through a metal foil connected to the wirelesscommunication chip that melts the foils and adheres to said first andsecond tabs.
 33. The method of claim 1, further comprising placing alayer over said wireless communication chip to hold said chip firmly inits desired location.
 34. The method of claim 33, wherein the layer is asealing layer.
 35. The method of claim 33, wherein the layer comprises amaterial suitable for printing.
 36. A method of producing a wirelesscommunication device, comprising: adjustably cutting a first tab for useas a first antenna element; adjustably cutting a second tab for use as asecond antenna element; and securing said first and second tabs to awireless communication chip, thereby forming a wireless communicationdevice, wherein adjustably cutting a first tab for use as a firstantenna element comprises using a plurality of selectively phaseablerollers to cut said first tab.
 37. A method of producing a wirelesscommunication device, comprising: adjustably cutting a first tab for useas a first antenna element; adjustably cutting a second tab for use as asecond antenna element; and securing said first and second tabs to awireless communication chip, thereby forming a wireless communicationdevice, wherein adjustably cutting a first tab for use as a firstantenna element comprises varying a position associated with a cuttingroller with respect to a center point so as to increase or decrease thelength of the tab.
 38. A method of producing a wireless communicationdevice, comprising: adjustably cutting a first tab for use as a firstantenna element; adjustably cutting a second tab for use as a secondantenna element; and securing said first and second tabs to a wirelesscommunication chip, thereby forming a wireless communication device,wherein adjustably cutting a second tab for use as a second antennaelement comprises using a plurality of selectively phaseable rollers tocut said second tab.
 39. A method of producing a wireless communicationdevice, comprising: adjustably cutting a first tab for use as a firstantenna element; adjustably cutting a second tab for use as a secondantenna element; and securing the first and second tabs to a wirelesscommunication chip, thereby forming a wireless communication device,wherein adjustably cutting the first and second tabs comprises: passinga conductive foil having a backing material through a first roller togenerate a first cut; passing the conductive foil having the backingmaterial through a second roller to generate a second cut therebyforming the first antenna element; and passing the conductive foilhaving a backing material through a third roller to generate a third cutthereby forming the second antenna element.
 40. The method of claim 39,further comprising separating waste material from said backing material.41. The method of claim 39, further comprising varying the relativephases of the rollers to vary the size of the first and second antennaelements.
 42. The method of claim 41, wherein varying the relativephases of the rollers comprises varying the phase of the second rollerwith respect to the first roller to vary the size of the first antennaelement.
 43. The method of claim 41, wherein varying the relative phasesof the rollers comprises varying the phase of the third roller withrespect to the first roller to vary the size of the second antennaelement.
 44. The method of claim 39, wherein the cut formed by thesecond roller overlaps the cut formed by the first roller.
 45. Themethod of claim 39, wherein the cut formed by the third roller overlapsthe cut formed by the first roller.
 46. The method of claim 39, whereinthe cut formed by the first roller comprises portions of cuts requiredto form the, first and second antenna elements.
 47. A method ofproducing a wireless communication device, comprising: adjustablycutting a first tab for use as a first antenna element; adjustablycutting a second tab for use as a second antenna element; and securingsaid first and second tabs to a wireless communication chip, therebyforming a wireless communication device, wherein adjustably cutting thefirst and second tabs comprises: passing a tape having a plurality oftabs disposed thereon under a first roller and a second roller; testingcapacitance formed by said tabs; varying the spacing between the firstand second rollers; and cutting two of the tabs to form the first andsecond antenna elements.
 48. The method of claim 47, wherein at leasttwo of the tabs are differently sized.
 49. The method of claim 47,wherein cutting two of the tabs to form the first and second antennaelements further comprises cutting a backing material.
 50. The method ofclaim 49, further comprising adhering said backing material to asubstrate.
 51. The method of claim 47, further comprising positioningsaid tape proximate a substrate prior to the step of testingcapacitance.